Digimat For Automotive Applications

DIGIMAT for Automotive
March 2011
Outline
Introduction
e-Xstream
DIGIMAT
Paradigm Shift: From CAE to Multi-Scale Modeling

Automotive Case Studies
Material Engineering
Structural Engineering
DIGIMAT outlook
Conclusions
Saturday, March 19, 2011
Copyright e-Xstream engineering, 2011
DIGIMAT
Is
The nonlinear multi-scale material
modeling platform
Used by
Material Engineers
Structural Engineers
At
Material Suppliers
Tier 1 (Material Users/Any Industry)
OEM (Material Users/Any Industry)
For
Accurate & Efficient FEA of
Composite Structures
Developed by e-Xstream engineering :

- Provider of Simulation Software & Engineering Services
- 100% Focused on Advance Material Modeling
DIGIMAT Users
Material Suppliers
Composites
Plastics
Rubber
Other: Nano Materials, Hard Metals, Graphite, Ceramics,
Material Users (i.e. OEMs & Tier Suppliers)
Automotive
Aerospace
Consumer (Electronics) Products
Defense
Industrial Products
Medical Devices
Other: Academic, R&D Institutes,
Key Benefits
Material Engineers:
To Understand & Optimize Material Behavior
To Support the Internal/External Users of the Materials
To Reduce Material Testing (Time & Cost)
To Improve Material Understanding
To Promote Material Usage
Structural Engineers
To Predict Structural Behavior
To improve FEA Predictivity & Accuracy
To Bridge the Gap between the Process & Structure
To Reduce Structure Prototyping & Testing (Time & Cost)
Automotive Composites
Matrix
Thermoplastics: PP, PA,
Thermosets: Epoxy,
Reinforcements
Fibers: Glass, Carbon, Natural,
Chopped (Short or long)
Distribution of Orientation (e.g. induced by injection)
Random
Continuous
UD
Woven
(Nano) Particles: Glass Bead, Mineral, Nano-Clay,
Manufacturing Processes
Molding: Injection, Compression (SMC, BMC)
RTM, vaRTM, RTM lite
Hand Layup
From CAE to Multi-Scale Modeling
PARADIGM SHIFT
Reinforced Thermoplastics
Standard FEA of a Reinforced Plastic Part

LS-DYNA
Element
Angle
& Loading
Strain-Rate
Temperature
Test Data:
Tenstion, Compression, Shear,
Postulated Material Models:
Elastic, Elasto-Plastic,
Simplified behavior:
Isotropic, Homogeneous,
Material
Process Material Structure
Material Processing
Moulding: Injection,
Compression,...
Drapage, AFP, ...
Material
Microsturcure
Material
Chracteristics
Chopped fibers
Continuous fibers:
UD/Woven
Nano, ...
Mechanical
Thermal
Electric, ...
Part/Vehicle
Performance
Digimat-MF, FE, MX
Digimat-MX, MAP, CAE
Structure Engineering
10
Injection: Part Filling & Fiber Orientation
Skin
Core
11
Reinforced Thermoplastics
xx
yy zz
xx yy zz
12
Nonlinear Mutli-Scale Modeling
FE model
Element
Test (or RE) Constituent Materials

Micromechanical Material Models
Stongly Couple to CAE
Accurate behavior
Material
13
From FEA to Multi-Scale Modeling

Process FEA
Injection Molding
Material Testing &

Modeling
Structural FEA
Drapage
Source: Campus
Source: Rhodia
Press Forming
Source: Rhodia
Compression Molding
EXPRESS
CADPRESS
e-Xstream
engineering,
2011 of their respective owners
Saturday,
19, exhaustive.
2011
14
Note: ThisMarch
list is not
The LogosCopyright
are Trademarks
or Registered
Trademarks
Improved MF Modeling
Composite behavior
Constituents Behavior
Constituents Behavior
Strong,
2-Way Coupling
Promising Material Candidates
Structure Engineering
DIGIMAT: Workflow
15
Automotive
Case Studies
MATERIAL
ENGINEERING
17
Mechanical: Youngs Modulus fct Angle

50
360
50
gate
Tensile specimen
100
Thickness=2,1mm
11000
Digimat
Experience
10000
8000
7000
6000
PA66+50w%GF, measured
16000
PA66+50w%GF modelled with Digimat, modelled a2

PA66+50w%GF modelled with Digimat, measured a2
Modulus (MPa)
Modulus (MPa)
9000
18000
14000
12000
10000
8000
5000
6000
4000
4000
20
40
60
Angle ()
80
100
20
40
60
angle ()
80
100
18
Mechanical: Nonlinear Stress-Strain

360
gate
50
50
Tensile specimen
100
200
180
True stress (MPa)
160
0_exp
15_exp
30_exp
45_exp
60_exp
90_exp
0 Digi
15_Digi
30_Digi
45_Digi
60_Digi
90_Digi
140
120
100
80
60
40
20
0
0
0,02
0,04
True
strain 2011
Copyright e-Xstream
engineering,
0,06
0,08
19
Thermo-Mechanical: E & CTE as fct (T)

Material: IXEF 1002
CTE Vs Temperature
0,00025
0.7928
0.0157
0.0525
0.0157
0.1789
0.0064
0.0525
0.0064
0.0283
Thermal expansion [C-1]
Average Orientation Tensor

0,0002
a11 Exp
a22 Exp
a33 Exp
a11 Digi
a22 Digi
0,00015
0,0001
a33 Digi
0,00005
0
0
50
100
150
200
250
Temperature [C]
Temperature
E11 Digi (MPa)
E11 Exp (MPa)
Diff.
E22 Digi (MPa)
E22 Exp (MPa)
Diff.
29 C
12 031
11 803
-1.91%
7 480
7 223
-3.57%
120 C
4 073
3740
-8.93%
1 281
1 257
-1.96%
Courtesy of Solvay:
20
Mechanical: UD Continuous Fiber CFRP
21
Thermal: Thermal Conductivity

Materials : thermal conductivity (isotropic)
Kerimid 601:
0.23
W/mK
Al2O3 :
30.7
W/mK
2-phase Microstructure : Kerimid matrix with Al2O3 fibers
matrix : Kerimid
inclusions : Al2O3 fibers
volume fraction : from 0.0 to 0.4
AR = 6
orientation : random in xy-plane (Random2D)
22
Electric : Electric Conductivity

Materials :
electrical conductivity (isotropic)
PE:
2.5 E-14 S/cm
Carbon : 50 S/cm (effective particle*)
Microstructure : 2-phase
matrix : PE
inclusions : Carbon
VF: 0 50%
AR: 1, 5.5 & 33
Orientation: Random3D
*
value obtained
from
composite
fraction e-Xstream
1.0 [Cai]
Copyright
Saturday,
March
19,
2011 with inclusion volume
engineering, 2011
23
Mechanical: Inter-Phase Debonding

Damage in the inter-phase
(macro strain 1%)
24
Electric: Electrical percolation in CNT
0.04
Max. Percolation threshold vs. Aspect ratio
Percolation threshold
0.035
Straight
Curved -
0.03
0.025
0.02
0.015
0.01
0.005
0
0
50
Aspect
100ratio
150
200
25
STRUCTURE
ENGINEERING
26
Technical Front End

DIGIMAT Material Model
PP-Matrix :
E= 1500 MPa
= 0.3
Fibres :
E = 72000 MPa
= 0.22
Volume Fraction = 19.46 % (40 % Weight Fraction)
Aspect ratio : 100 (Long Fibers)
Orientation : MOLDFLOW 5.1
www.renault.com
FEA Model
# Elements =12632 (S3R)

# Nodes = 6365
# DOF = 38190
Material : PP-LGF with DIGIMAT 1.6
Initial Stresses: MOLDFLOW 5.1
Courtesy of:
27
Technical Front End: Stiffness

P2: 20daN
P3 : 20daN
P1: 20daN
Fixed
Structural Stiffness (MDA-Test)/Test
P1
-3.75%
P2
+8.07%
P3
-6.97%
Courtesy of:
28
Eingen Frequency [Hz]
Technical Front End: Vibration
Test
MDA Predictions
10
11
12
13
14
15
16
17
19
18
Mode Number
Courtesy of:
29
Airbag Container: Stiffness

Injection Molding Mesh:
Number of nodes/Elements: 584,123/3,369,976
Structural Mesh:
Number of nodes/Elements: 368,852/194,794
Material:
AKULON K224-PG8 (40% Glass filled

Impact Modied Polyamide)
Matrix: Impact Modified Polyamide
type = elastoplastic
Young Modulus = 2350 MPa
Poisson Ratio = 0.38
Yield stress =30 MPa
Fibers: E-Glass
Type = elastic
Density = 2.54 E+3
Young Modulus = 72 000 MPa
Poisson Ratio = 0.22
Weight fraction = 40%
Aspect ratio (L/D) = 20
Orientation = Injection Molding (.xml)
RF @ Imposed D
Experimental Force
DIGIMAT to Abaqus
Linear
(to 10.5mm)
~ 6477 N
6203.49 N
Cyclic
(to 7mm)
~ 4765N
3949.18 N
CourtesyMarch
of: AUTOLIV
Saturday,
19, 2011 & DSM
Difference
-4.2%
-17 %
30
Quasi-Static/Monotonic: Elasto-Plastic
DIGIMAT Material
Courtesy
of: AUTOLIV
Saturday, March
19, 2011 & DSM
31
Impact: Elasto-ViscoPlastic DIGIMAT

Material
Courtesy
of: AUTOLIV
Saturday, March
19, 2011 & DSM
32
Airbag Container: Failure

Akulon K224-PG6
Failure
Courtesy of :TRW & 33

DSM
Von Mises Stress (Pa)
Airbag Container: Failure
Failure area
t = 0.0054 s
t = 0.0084s
t = 0.0088s
Courtesy of :TRW & 34

DSM
Roof System Bearing: Local Stiffness
35
Roof System Bearing: Global Stiffness
36
Oil Pan
Thermo-elasto-viscoplastic
PAGF oil pan
Reverse Engineering
Boundary conditions
Displacement / Force
Temperature load
Pressure
Creep
Oil Pan: Anisotropic Creep

Thermo-elasto-viscoplastic
PA/GF35 oil pan
Vastly different results
Isotropic:
dmax = 4.1 mm
Anisotropic: dmax = 3.1 mm
dISO
dANISO
Sun Roof Front Panel
39
Sun Roof Pannel: Stiffness

LC 1
LC 2
LC 4
LC 3
40
Lower B Pillar Insert

Part size : # 600 * 170 * 85 mm
Thickness : from 2 to 5.2 mm
Part weight : 2.4 kg
Material : PA6GF35
Dr. F. Braymand, L&L Products

Improved Physical Property Prediction of Short
FRP (Session 5)
41
DIGIMAT Nonlinear Anisotropic Material
42
Lower B Pillar Insert: Modal Analysis
43
Lower B Pillar Insert: Crash & Failure
Good failure
location
Bad failure
location
44
M.M.I Beam
45
Digimat-CAE: Impact Model (MMI Beam)

Mass of 18 kg
3 m/s for 5 gates

4,8 m/s for 2 gates
Failure at the same time

46
Digimat-CAE: Force & Failure (MMI Beam)
Failure in experimental and MMI
Failure with isotropic approach
Good correlation in force and failure

47
CPU Performance: Crash (Explicit)
48
CPU Performance: Quasi-Static (Implicit)
49
Technology
Roadmap
Performance
Thermal
Stiffness
Vibration
Crash
Electric
Creep
Fatigue
Failure
Materials
Plastics (LFT)
Rubber
Hard Metals
Nano
HoneyComb
Carbon
FEA
Structural/Implicit
Structural/Explicit
UD & Woven
composites
DIGIMAT
Processes
Multi-Scales
Injection Molding
Macro
Fiber Drapage
Auto. Fiber Plac
Micro
Nano
50
DIGIMAT Dev Plan 2011

DIGIMAT 4.2 (Jul. 11)
Consolidate
DIGIMAT 4.3 (Dec. 11)

Consolidate
Fast/Easy/Robust
Fast/Easy/Robust
FEA
FEA
MSC: Marc
LSTC: Dyna Implicit
MSC: Nastran
ANSYS OEM
Materials
Materials
LFT
CFRP
LFT
CFRP
Process: Drapage
Process: Drapage
Simulayt
FiberSim
Perfromance: Strength
Fatigue
Perfromance: Strength
Fatigue
nCode: DesignLife
LMS: VirtualLab Durability
FEMFAT
Crash
Crash
51
Conclusions
Composite materials offer a great opportunity for weight and
emissions reduction + many other advantages
There is no unique composite solution
Material
Thermoplastic vs. Thermosets
Carbon vs Glass vs
Chopped vs continuous fibers
Manufacturing Process
Injection vs. RTM vs. Compression vs. Drapage
The two main barriers to using composites

Price
Familiarity
Nonlinear Multi-Scale Modeling Technology can help

Understanding composite behavior Increase Familiarity
Optimizing composite design Reduce the material bill
Reducing the overall time & cost of developing composite
materials & structures
52

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DIGIMAT for Automotive

Paradigm Shift: From CAE to Multi-Scale Modeling

Saturday, March 19, 2011

Copyright e-Xstream engineering, 2011

Developed by e-Xstream engineering :

Copyright e-Xstream engineering, 2011

Material Users (i.e. OEMs & Tier Suppliers)

Saturday, March 19, 2011

Copyright e-Xstream engineering, 2011

Copyright e-Xstream engineering, 2011

(Nano) Particles: Glass Bead, Mineral, Nano-Clay,

Copyright e-Xstream engineering, 2011

From CAE to Multi-Scale Modeling

Saturday, March 19, 2011

Copyright e-Xstream engineering, 2011

Saturday, March 19, 2011

Copyright e-Xstream engineering, 2011

Standard FEA of a Reinforced Plastic Part

Saturday, March 19, 2011

Copyright e-Xstream engineering, 2011

Process Material Structure

Copyright e-Xstream engineering, 2011

Injection: Part Filling & Fiber Orientation

Saturday, March 19, 2011

Copyright e-Xstream engineering, 2011

Nonlinear Mutli-Scale Modeling

Test (or RE) Constituent Materials

Saturday, March 19, 2011

Copyright e-Xstream engineering, 2011

From FEA to Multi-Scale Modeling

Material Testing &

Saturday, March 19, 2011

Copyright e-Xstream engineering, 2011

Promising Material Candidates

Copyright e-Xstream engineering, 2011

Mechanical: Youngs Modulus fct Angle

PA66+50w%GF modelled with Digimat, modelled a2

Saturday, March 19, 2011

Copyright e-Xstream engineering, 2011

Mechanical: Nonlinear Stress-Strain

True stress (MPa)

Saturday, March 19, 2011

Thermo-Mechanical: E & CTE as fct (T)

Thermal expansion [C-1]

Average Orientation Tensor

E11 Digi (MPa)

E11 Exp (MPa)

E22 Digi (MPa)

E22 Exp (MPa)

Saturday, March 19, 2011

Copyright e-Xstream engineering, 2011

Mechanical: UD Continuous Fiber CFRP

Saturday, March 19, 2011

Copyright e-Xstream engineering, 2011

Thermal: Thermal Conductivity

Saturday, March 19, 2011

Copyright e-Xstream engineering, 2011

Electric : Electric Conductivity

Mechanical: Inter-Phase Debonding

Saturday, March 19, 2011

Copyright e-Xstream engineering, 2011

Electric: Electrical percolation in CNT

Max. Percolation threshold vs. Aspect ratio